Non-combustible electronic aerosol delivery system

ABSTRACT

The present disclosure provides an article for use with a non-combustible aerosol delivery system, the article comprising a reservoir configured to hold a supply of aerosolizable material; wherein the reservoir comprises a reservoir housing having one or more internal boundary walls defining a first volume, wherein the article further comprises a spacer fully or partially located within the first volume of the reservoir housing, the spacer being configured to reduce the available fill volume of the reservoir, such that a second volume of the reservoir housing available for storing aerosolizable material is smaller than the first volume.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a National Phase entry of PCT Application No. PCT/GB2021/050762, filed Mar. 26, 2021, which claims priority from Great Britain Application No. 2004733.8, filed Mar. 31, 2020, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to non-combustible aerosol delivery systems and a method of manufacturing an aerosol delivery system.

BACKGROUND

Electronic aerosol delivery systems such as electronic cigarettes may operate by generating aerosol or vapor for user inhalation from a supply of aerosolizable material such as a source liquid (e.g., e-liquid) or a source solid (e.g., a plant-based material). Techniques for vapor generation include heating the aerosolizable material with a resistive or inductive heating element or feeding a source liquid to a vibrating perforated membrane. The aerosolizable material is typically held in a reservoir where, for instance, a source liquid may be held as free liquid or within an absorbent matrix such as cotton wadding. When the aerosolizable material has been consumed, a new supply is required to continue vapor production. Some systems are wholly disposable so that the user simply replaces the complete system when the aerosolizable material is exhausted. Other systems allow the user to refill the reservoir, or to replace a component of the system that includes the reservoir with a new component containing a fresh supply of aerosolizable material.

There is a desire to provide electronic aerosol delivery systems having different aerosolizable material holding capacities. This may be, for example, to provide users with different versions of a disposable cartridge, filled with different quantities of aerosolizable material. In some cases the aerosolizable material comprises a liquid, and cartridges are provided for sale pre-filled with a given volume of liquid. A reservoir design of fixed internal volume could in principle be filled with different quantities of a liquid (with the remaining volume comprising air or another gas), providing variants of an aerosol delivery device and/or cartridge having a different liquid holding capacity. However entrapped gas within a reservoir may contribute towards liquid leakage, due, for example, to expansion and contraction of the gas due to changing ambient temperature and/or pressure.

Accordingly, approaches for mitigating these issues are of interest.

SUMMARY

According to a first aspect, there is provided an article for use with a non-combustible aerosol delivery system, the article comprising a reservoir configured to hold a supply of aerosolizable material; wherein the reservoir comprises a reservoir housing having one or more internal boundary walls defining a first volume, wherein the article further comprises a spacer fully or partially located within the first volume of the reservoir housing, the spacer being configured to reduce the available fill volume of the reservoir, such that a second volume of the reservoir housing available for storing aerosolizable material is smaller than the first volume.

According to a second aspect, there is provided a spacer for use with an non-combustible aerosol delivery system comprising a reservoir configured to hold a supply of aerosolizable material, wherein the reservoir comprises a reservoir housing having one or more internal boundary walls defining a first volume, wherein the spacer is configured to be fully or partially located within the first volume of the reservoir housing; and wherein the spacer is configured to occupy a portion of the first volume of the reservoir housing, such that a second volume of the reservoir housing not occupied by the spacer is smaller than the first volume.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the disclosure will now be described in detail by way of example only with reference to the following drawings in which:

FIG. 1 shows a cross-sectional view through an example aerosol delivery system in which a reservoir volume modifying spacer may be used in accordance with examples of the present disclosure;

FIG. 2 shows a perspective view of an example aerosol delivery system in which a reservoir volume modifying spacer may be used in accordance with examples of the present disclosure;

FIG. 3 is a perspective external view of the cartomizer portion of the aerosol delivery system of FIG. 1 ;

FIG. 4A shows a schematic view of a reservoir for use in an aerosol delivery system as described herein;

FIG. 4B shows a schematic view of a spacer for use in an aerosol delivery system as described herein;

FIG. 4C shows a schematic view of a spacer inside a reservoir for use in an aerosol delivery system as described herein;

FIG. 4D shows a schematic view of a spacer inside a filled reservoir for use in an aerosol delivery system as described herein;

FIG. 5A schematically shows a reservoir for use in an aerosol delivery system as described herein;

FIGS. 5B, 5C and 5D schematically show examples of joining techniques used to join together portions of the reservoir shown in FIG. 5A;

FIG. 6A shows a reservoir housing having an aperture according to the present disclosure;

FIG. 6B shows the housing of FIG. 6A following sealing of the aperture;

FIGS. 7A and 7B schematically show examples of a spacer element according to the present disclosure;

FIGS. 8A to 8D schematically show an example of a spacer element and reservoir housing according to the present disclosure;

FIGS. 9A and 9B schematically show examples in which a spacer element is fixed into position within a reservoir according to the present disclosure;

FIGS. 10A to 10C schematically show examples of an approach according to which a spacer element may be incorporated into a reservoir during a molding process;

FIG. 10D schematically shows an example of a reservoir housing portion which has had a spacer element incorporated during molding;

FIGS. 10E and 10F schematically show different reservoir housings comprising reservoir housing portions molded using the mold shown in FIGS. 10A to 10C;

FIG. 11 schematically shows a reservoir housing comprising two reservoir housing portions and joined together according to the present disclosure;

FIG. 12 schematically shows a reservoir housing to which a spacer element comprising a volume of liquid has been introduced;

FIG. 13 schematically shows a reservoir housing to which a spacer element comprising a volume of granules has been introduced.

DETAILED DESCRIPTION OF THE DRAWINGS

Aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed/described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

As described above, the present disclosure relates to (but is not limited to) electronic aerosol or aerosol delivery systems, such as non-combustible aerosol delivery systems. Throughout the following description the terms “aerosol delivery system” and “electronic cigarette” may sometimes be used; however, it will be appreciated these terms may be used interchangeably with aerosol (or vapor) provision system or device. The disclosure is also applicable to hybrid devices and systems configured to deliver nicotine or other substances both by vaporizing aerosolizable material such as a liquid and/or by heating a solid substrate such as tobacco or other plant-derived material directly, and/or by passing vapor or aerosol through such a substrate. The various terms noted above should be understood to include such devices. Similarly, “aerosol” may be used interchangeably with “vapor”. The term ‘aerosol generating component’ is used herein to refer to any component or set of components which is used to generate aerosol or vapor from aerosolizable material. In some embodiments, the aerosol generating component is a heater capable of interacting with the aerosolizable material so as to release one or more volatiles from the aerosolizable material to form an aerosol. In some embodiments, the aerosol generating component is capable of generating an aerosol from the aerosolizable material without heating. For example, the aerosol generating component may be capable of generating an aerosol from the aerosolizable material without applying heat thereto, for example via one or more of vibrational, mechanical, pressurization or electrostatic means.

As used herein, the term “component” is used to refer to a part, section, unit, module, assembly or similar of an electronic cigarette that incorporates several smaller parts or elements, often within an exterior housing or wall. An electronic cigarette may be formed or built from one or more such components, and the components may be removably connectable to one another, or may be permanently joined together during manufacture to define the whole electronic cigarette.

Non-combustible aerosol delivery systems can operate by generating aerosol from an aerosolizable material, including by heating or by vibration. Commonly, the aerosolizable material comprises a liquid, stored in a reservoir or tank within the system, and a new supply of liquid is required when the reservoir becomes empty. In some systems, the reservoir is comprised in a cartridge or cartomizer′ which is removably connectable to a control unit. When the cartridge and control unit are connected, an interface between them may be configured to enable aerosolizable material, energy, and/or air or aerosol to pass between the cartridge and control unit. The control unit will generally be intended for multiple uses, and comprises one or more power sources, control circuitry, sensors (such as a puff sensor), user input devices (such as buttons). The control unit may also comprise an aerosol generating component such as a heater. A cartridge will often be manufactured for a single use, and is not designed such that the reservoir can be refilled by the user once the aerosolizable material has been depleted. Spent cartridges may be disposed of after use, or collected for recycling, refurbishment and/or refilling by a third party. In addition to containing the reservoir, a cartridge or cartomizer may comprise one or more air passages through which air and/or aerosol may pass when a user inhales on the device. A cartridge and/or cartomizer may also contain an aerosol generating component, which is provided with energy to aerosolize aerosolizable material from the reservoir when the device is activated by a user. Generic terms such as “aerosolizable material”, “aerosol precursor fluid” or “aerosolizable fluid” may be used to encompass any material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosolizable material may, for example, be in the form of a solid, liquid or gel which may or may not contain nicotine and/or medicaments and/or flavorants. In some embodiments, the aerosolizable material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolizable material may for example comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid. The present disclosure uses the term “liquid” extensively, but this is for simplicity only, and “liquid” should be understood to include gels and any other aerosolizable materials unless stated otherwise. The aerosolizable material, as a liquid or a gel, may be held in a reservoir in a “free-flowing” form, in that it is not absorbed into a matrix of absorbent material such as a sponge or wadding placed inside the reservoir.

FIG. 1 is a cross-sectional view through an example aerosol delivery system 100 in which a reservoir volume modifying spacer may be used in accordance with examples of the present disclosure. The aerosol delivery system 100 comprises two main components, namely a cartomizer/cartridge 200 and a control unit or power unit 300. The cartomizer 200 includes a chamber, tank or reservoir 21 configured to hold a supply of aerosolizable material (e.g., a liquid), an aerosol generating component 22 (e.g., a heater) to generate vapor from the liquid, and a mouthpiece 250. The cartomizer 200 is able to supply aerosolizable material from the reservoir for aerosolisation by the aerosol generating component 22. In the present example, the cartomizer further includes a wick 23 (or similar facility) to transport a small amount of liquid from the reservoir 21 to a heating location on or adjacent to an aerosol generating component comprising a heater 22. The control unit 300 includes within a housing 33 a re-chargeable cell or battery 31 to provide power to the aerosol delivery system 100, and control circuitry 32 (e.g., comprising a printed circuit board, which may further comprise components such as a CPU and/or MCU, and or ASIC configured, for instance via firmware or other suitable instructions) for generally controlling the aerosol delivery system 100. When the control circuitry receives an activation signal indicating a user is seeking to generate aerosol (e.g., a signal from a puff sensor or button), the aerosol generating component 22 is controlled by the PCB 32 in dependence on the activation signal to aerosolize a portion of aerosolizable material. This comprises controlling a supply of energy to the aerosol generating component 22. This will generally be achieved by supplying current from the battery 31 to the aerosol generating component. This may be achieved via direct electrical connections between the battery 31 and the aerosol generating component 22, or by wireless energy transmission, such as inductive heating, using a drive coil (not shown) in the control unit to provide energy to an aerosol generating component 22 comprising a susceptor. Power supply to the aerosol generating component 22 may be controlled via any known approach such as DC to DC conversion or pulse width modulation (PWM). Aerosol produced by the aerosol generating component 22 is provided for inhalation by a user through a mouthpiece 250. It will be appreciated in some examples the control circuitry may not comprise a controller such as a CPU or MCU, but may comprise a more simple configuration comprising, for instance, a switch directly disposed in an electrical path between the power supply 31 and the aerosol generating component 22.

It will be appreciated that although the present example describes a cartridge 200 which comprises an aerosol generating component and a mouthpiece (e.g., a cartomizer), in other examples the cartridge may not comprise one or both of these elements. For example, the control unit 300 may comprise the aerosol generating component (not shown), and the cartridge 200 is configured to transport aerosolizable material to a location within the aerosol delivery system 100 where it can be aerosolized by the aerosol generating component. This may comprise aerosolizable material being transported via a suitable transport means from the reservoir in the cartridge 200 to an atomizing location in the control unit. Alternatively, an aerosol generating component 22 (not shown) associated with the control unit 300 may be configured such that it is received by the cartridge 200 when the cartridge 200 and control unit 300 are joined together. The aerosol generating component may be received into a location within, abutting, or proximate to either the reservoir 21 or a wick 23 connected to the reservoir 21 as set out further herein.

In the present example, the cartomizer 200 and the control unit 300 are detachable from one another by separation in a direction along a longitudinal axis of the device, indicated in FIG. 1 by the arrows S, but are joined together (as in FIG. 1 ) when the device 100 is in use so as to provide mechanical and electrical connectivity between the cartomizer 200 and the control unit 300. Hence, the cartomizer and the control unit are separably connectable; they can be joined (coupled) together or separated apart according to user need. In this particular example, when the liquid in the reservoir 21 has been depleted, the cartomizer 200 is removed and a new cartomizer is attached to the control unit 300. Accordingly, the cartomizer 200 may sometimes be referred to as a disposable portion of the aerosol delivery system 100, while the control unit 300 represents a re-usable portion. Alternatively, the cartomizer may be configured so that the reservoir is refillable with liquid, and the cartomizer may or may not require detachment from the control unit for access to a filling port. Though this example shows a reservoir 21 contained in a cartridge 200 which is detachable from a reusable control unit 300, in other examples the reservoir 21 may be contained within the control unit 300. The control unit in such instances may be configured to be reused, and the reservoir will in such instances be configured to be refilled by the user, for example via an aperture, refill valve, and/or removable plug or housing.

FIG. 2 is an external perspective view of the aerosol delivery system 100 of FIG. 1 , in its assembled configuration with the cartomizer 200 coupled to the control unit 300 so that the aerosol delivery system is ready for use. The orientation is different from FIG. 1 , as indicated by the xyz axes.

FIG. 3 is a perspective external view of the cartomizer 200 of the aerosol delivery system of FIG. 1 . The cartomizer 200 comprises two main portions (at least from an external viewpoint). In particular, there is a lower or base portion 210 and an upper portion 220. The upper portion 220 is shaped to provide the mouthpiece 250 of the aerosol delivery system. When the cartomizer 200 is assembled with the control unit 300, the base portion 210 of the cartomizer sits within the upper part of the housing 33 of the control unit 300, and hence is not externally visible, whereas the upper portion 220 of the cartomizer protrudes above the control unit 300, and hence is externally visible. Accordingly, the depth and width of the base portion 210 are smaller than the depth and width of the upper portion 220, to allow the base portion 210 to fit inside the control unit 300.

The base portion 210 has a lower face defined by a bottom wall 211. The bottom wall includes two larger holes 212A, 212B on either side of a smaller hole 214 which is for air inlet into the cartomizer interior. The larger holes 212A and 212B are used to accommodate positive and negative electrical connections from the control unit 300 to the cartomizer 200, provided by the conductive connectors 35 shown in FIG. 1 . When a user inhales through the mouthpiece 250, the device 100 is activated and air flows into the cartomizer 200 through the air inlet hole 214 (via a pathway leading from ventilation slots 24 (see FIG. 1 ) defined at the juncture between the top edge of the control unit housing 33 and a lip 240 between the lower portion 210 and the upper portion 220 of the cartomizer 200). This incoming air flows past the aerosol generating component (not visible in FIG. 3 ), which receives electrical power from the battery 31 in the control unit 300 so as to aerosolize liquid supplied from the reservoir 21 by the wick 23. This vaporized liquid is then incorporated or entrained into the airflow through the cartomizer, and hence is drawn out of the cartomizer 200 through the mouthpiece 250 for inhalation by the user.

Other features shown in FIGS. 1 to 3 are not described further here as not being relevant to the present disclosure.

Note also that the system shown in FIGS. 1 to 3 is purely by way of example, and the present disclosure is applicable to other shapes and configurations of aerosol delivery systems in which the various components are differently arranged. For example, the device may be unitary, and not separable into a cartomizer part and a control or power part. The reservoir may be separately replaceable or removable for refilling distinct from other components, perhaps provided in a cartridge format, or may be comprised within a cartomizer part together with an aerosol generating component such as a heater for replacement together, as in the FIG. 1 arrangement. A cartomizer and a control unit might be arranged linearly as in FIG. 1 , or in a side-by-side arrangement. Alternatively, the cartomizer or cartridge 200 may take the form of a ‘pod’ which is fully received into the control unit 300 (for instance into a hatch or recess) such that some or all of the cartridge 200 is hidden from the user when joined to the control unit 300 for use.

FIG. 4A shows in highly simplified schematic form a reservoir 21 for use in an aerosol delivery system as described further herein, for example, a reservoir 21 comprised in a cartridge or cartomizer 300 for an aerosol delivery device as shown schematically in FIG. 1 . The reservoir 21 comprises a space, void or cavity V1. The volume of the space V1 is defined as the volume bounded by one or more boundary walls 2120. The volume V1 typically excludes any components which may pass through the reservoir 21, e.g., tubes for aerosol flow. In the simplified example of FIG. 4A, four boundary walls, 2121, 2122, 2123 and 2124, are shown. The boundary walls comprise internal surface portions of a reservoir housing 2110, and the number of boundary walls and their topology is dependent on the overall shape of the reservoir housing 2110. The overall shape of the reservoir housing 2110 is defined by at least by the topology of the external surface 2130 and the topology of the internal boundary walls 2120. The overall shape of the reservoir housing can take a variety of forms, and may be selected in accordance with design constraints of the aerosol delivery system 100. For example, in the exemplary cartridge 200 shown schematically in FIG. 1 , the reservoir housing 2110 has a curved external surface portion 2130 which comprises part of the external surface of the cartridge 200. The shape and number of the internal boundary walls 2120 is determined by the arrangement of other components in the cartridge 200. For example, in FIG. 1 , the reservoir is bisected by an airflow passage 26, and the external wall 27 of the tube comprising the airflow passage 26 comprises one of the internal boundary walls 2120 of the reservoir 21. Also shown in FIG. 1 are exemplary internal walls 2121 and 2122 which form part of the internal boundary surface of the reservoir 21, defining the maximum volume V1 available for holding aerosolizable material. Though in FIG. 1 an external surface portion 2130 of the cartridge 200 comprises a portion of the external surface of the aerosol delivery system 100 when in use, in other instances this is not the case, and the external surface 2130 of the reservoir housing may be fully internal to an exterior housing of cartridge 200 or control unit 300.

FIG. 4B schematically shows a spacer element 400 in accordance with the present disclosure, which is configured to be introduced to a location fully or partially within the volume V1 of the reservoir 21, internal to the boundary walls 2120 (e.g., boundary walls 2121, 2122, 2123 and 2124 shown in FIG. 4A). The spacer element 400 in this example comprises four external wall portions 411, 412, 413, 414. As set out further herein, the structure and material(s) comprising the spacer element are selected such that the spacer element comprises regions which are impermeable to aerosolizable material. In this regard, the structure and material(s) comprising the spacer element will be dependent upon a specific aerosolizable material or range of aerosolizable materials to be used in aerosol provision systems in which the spacer element is to be used. FIG. 4C shows the reservoir 21 from FIG. 4A with the spacer element 400 located at a position within the boundary walls 2121, 2122, 2123 and 2124. The spacer element is configured with a volume V2 which is impermeable to one or more aerosolizable materials to be stored in the reservoir 21. In some examples the volume V2 will comprise the entire volume enclosed by the external wall portions 411, 412, 413, 414. In such examples, the external wall portions will be fully impermeable to the aerosolizable material(s). In other examples, the spacer element 400 may be configured such that only some regions of the spacer element are impermeable to the aerosolizable material(s). For instance, the spacer element 400 may comprise a foam material or fibrous material having pore spaces within the volume enclosed by the external wall portions 411, 412, 413, 414 which may be accessed by the aerosolizable material(s). However what is significant is that the volume V2 of spacer element 400 which is impermeable to one or more aerosolizable materials is such that when the spacer element is present in the reservoir 21, a volume V1′ available for holding aerosol precursor material within the reservoir 21 is less than the total volume V1 defined by the space internal to the internal boundary walls 2121, 2122, 2123 and 2124 of the reservoir housing 2110. FIG. 4D, which will be recognized from FIG. 4C, shows the reservoir 21 with the spacer element 400 in place, and the volume V1′ filled with aerosolizable material, indicated by the shaded region. The volume V2 of the spacer element can be selected such that the maximum overall internal fill volume V1 of the reservoir housing 2110 can be reduced to an appropriate volume V1′ for the application at hand. For instance, where an aerosol delivery system comprising a reservoir is used to provide a controlled substance such as nicotine, regulations may differ between countries as to the maximum volume of nicotine-containing aerosolizable material which may be stored and/or sold in an individual aerosol delivery system and/or cartridge/cartomizer. For example, a first country may permit sale of cartridges/cartomizers with a 2 ml maximum volume of aerosolizable material, and a second country may permit sale of cartridges/cartomizers with a 1 ml maximum volume of aerosolizable material. For cartridges/cartomizers marketed in the first country, a reservoir with a volume of V1=2 ml may be provided, with no spacer. For cartridges/cartomizers marketed in the second country, a spacer with a volume of V2=1 ml may be introduced to the reservoir, providing a reduced maximum remaining fill volume of V1′=1 ml. Significantly, this approach allows different fill volumes to be specified whilst ensuring that in each instance, the available fill volume can be entirely filled with aerosolizable material. Where the aerosolizable material comprises a liquid, this may mitigate issues with leakage due to expansion/contraction of entrapped air. For instance, in the above example, in the absence of a spacer, filling a 2 ml reservoir with only 1 ml of liquid would leave 1 ml of air or other gas in the reservoir. Thermal expansion/contraction, and pressure changes during transit of cartridges/cartomizers may cause leakage of liquid in such an example. The provision of a spacer 400 may thereby permit different fill volumes to be specified for reservoirs having the same base volume V1, and avoid the need to specify different reservoir geometries (with associated increase in tooling costs) to provide aerosol delivery systems/cartridges/cartomizers with different fill volumes. This approach can also allow for the production of a single size cartridge/cartomizer for multiple territories, which can reduce manufacturing costs since the required volume can simply be achieved by utilizing an appropriately sized spacer.

The reservoir housing 2110 may be formed in a number of ways. The reservoir housing 2110 will in general be configured to prevent aerosolizable material from egressing the space defined internal to the boundary wall(s) 2120, except for one or more apertures to permit aerosolizable material to be transported to an aerosol generating component (for instance, via a wick 23 which partially enters the reservoir space via an aperture in the reservoir housing 2110). A reservoir configured to hold a quantity of aerosolizable material comprising liquid will generally be formed of material(s) which are substantially impermeable to the liquid, and/or lined with such a material. The reservoir housing 2110 may comprise one or more further apertures to enable aerosolizable material to be introduced to the internal space (i.e. to fill/refill the reservoir) and/or to enable air into the reservoir as aerosolizable material is depleted, in order to equalize pressure within the reservoir. Such apertures will generally comprise a one-way valve arrangement to prevent egress of aerosolizable material via the aperture(s). In some examples, the reservoir housing 2110 comprises a unitary, integrally formed component. In some examples the reservoir housing 2110 is formed from a plastics material, and manufactured by a process such as injection molding. In some examples the reservoir housing 2110 is formed from a glass or ceramic material and formed by a suitable process known in the art, for example a thermoforming process. In some examples the reservoir housing 2110 is formed from a metallic material, and may be formed by a thermal molding process, or by a machining process, or from sheet metal stock by a mechanical stamping or other forming process. Apertures in the reservoir housing 2110 may be formed during a molding process, and/or added later via processing techniques such as machining or laser cutting.

In other examples, the reservoir housing 2110 is not integrally formed, but is manufactured by joining together a plurality of housing portions. FIG. 5A shows a reservoir housing 2110 comprised of a first reservoir housing portion 2111 and a second reservoir housing portion 2112 which are joined together using a suitable approach. The first reservoir housing portion 2111 comprises three boundary walls 2121, 2122 and 2123 which comprise internal boundary walls of the reservoir housing 2110 when the two reservoir housing portions 2111 and 2112 are joined together. The second reservoir housing portion 2112 comprises three boundary walls 2124, 2125 and 2126 which comprise internal boundary walls of the reservoir housing 2110 when the two reservoir housing portions 2111 and 2112 are joined together. Each of the reservoir housing portions 2111 and 2112 may be formed from any of the materials and according to any of the manufacturing approaches described further herein for forming a unitary reservoir housing. When the two reservoir housing portions 2111 and 2112 are joined together to form the reservoir housing 2110, the boundary walls 2121, 2122, 2123, 2124, 2125 and 2126 together define the maximum fill volume V1 of the reservoir housing.

The reservoir housing portions 2111 and 2112 may be joined together to assemble the reservoir housing 2110 using any suitable joining method, for example welding (e.g., ultrasonic welding), adhesive bonding, solvent bonding, and permanent mechanical fastening. FIGS. 5B, 5C and 5D schematically show examples of joining techniques used to join together reservoir housing portions 2111 and 2112 at joining interface(s) 2210 shown schematically in FIG. 5A. FIGS. 5B and 5C schematically show examples of a mechanical fastening approach to joining reservoir housing portions 2111 and 2112. According to this approach an interface portion 2310 of a first reservoir housing portion 2111 is provided with a latching tab 2311. An interface portion 2320 of a second reservoir housing portion 2112 is provided with a latching recess 2321. When the first and second reservoir housing portions are brought together, resilience in latching tab 2311 and/or latching recess 2321 causes the latching tab 2311 to be received into the latching recess 2321, causing the first and second reservoir housing portions to be mechanically coupled together, as shown schematically in FIG. 5C. The respective shapes and resilience properties of the latching tab and latching recess are selected such that the interface 2210 formed by the engaged latching tab is substantially impermeable to aerosolizable material. A sealing material and/or gasket may be introduced to the interface between the interface portions 2310 and 2320 to facilitate the sealing of the reservoir from egress of aerosolizable material. The respective shapes and resilience properties of the latching tab 2311 and latching recess 2321 may be further selected such that the first and second reservoir housing portions 2111 and 2112 cannot be separated without causing damage to the latching tab 2311 and/or latching recess 2321. As shown in FIG. 5B, a latching surface 2312 of the latching tab 2311 is configured to abut a latching surface 2322 of the latching recess when the latching tab is received into the recess, preventing the latching tab from being withdrawn from the latching recess without damage. The latching tab and recess arrangement shown in FIGS. 5B and 5C is only one exemplary arrangement, and other mechanical fastening approaches may be used. For instance the first reservoir housing portion 2111 may be shaped as an end-plug to be partially or fully received into an opening or aperture of the second reservoir housing portion 2112, with outer surfaces of the first and second reservoir housing portions being provided with cooperating features (e.g., tabs, dimples, recesses, slots) over their contacting portions, such that the first reservoir housing portion 2111 is mechanically fastened to the second reservoir housing portion 2112 when it is received into the open end of the second reservoir portion 2112. Other mechanical fastening approaches include riveting and threading using locking threads.

FIG. 5D schematically shows a bonding approach to joining reservoir housing portions 2111 and 2112 at an interface 2210. Bonding of reservoir housing portions 2111 and 2112 may be achieved by introducing an adhesive at a contact surface between an interface portion 2310 of the first reservoir housing portion 2111 and an interface portion 2320 of the second reservoir housing portion 2111, forming an adhesive bonding region 2400 between the reservoir housing portions 2111 and 2112. The adhesive may comprise a solvent which partially dissolves/softens the material comprising the first and/or second reservoir housing portions 2111 and 2112, causing them to be joined together. In other examples, the adhesive bonding region 2400 may be formed by welding (e.g., ultrasonic or thermal welding). FIGS. 6A and 6B schematically show a reservoir-forming approach in which a reservoir housing 2110, which may comprise a plurality of joined reservoir housing portions 2120, is sealed using a suitable sealing approach. FIG. 6A shows a reservoir housing 2110 having an aperture 2500. FIG. 6B shows the housing 2110 following sealing of the aperture 2500. The aperture may be sealed using a welding approach, or through insertion of a sealant or adhesive into the aperture, forming a sealing portion 2600. As set out further herein, the aperture 2500 may be used to introduce a spacer element 400 into the reservoir, following which the aperture may be sealed to prevent removal of the spacer element.

In the foregoing it will be appreciated that there may be any number of reservoir housing portions joined together to form the reservoir housing, and that each of the plurality of reservoir housing portions may comprise any number of boundary walls which form internal boundary walls of the reservoir housing 2110 when the plurality of reservoir housing portions are joined together. It will also be appreciated that any combination of the abovementioned joining approaches may be used to join together the plurality of reservoir housing portions to form the reservoir housing. The geometry of each of the housing portions, and the geometry of the reservoir housing 2110 is not of particular significance, and can be tailored to necessary design and manufacturing constraints. The reservoir housing may also comprise a flexible container formed in the manner of a bladder.

According to examples of the present disclosure, a spacer element is provided, which can be inserted into the reservoir to reduce the total fill volume of the reservoir from the maximum fill volume V1 to an available fill volume V1′, whereby V1′<V1. The spacer element is configured such that it cannot be removed from the reservoir following insertion. As set out further below, this can comprise introducing the spacer element into the reservoir during manufacture of the reservoir, for example by inserting the spacer element through an aperture in a reservoir housing and subsequently sealing the aperture, and/or by joining together a plurality of reservoir housing portions around a spacer element to form a reservoir housing, such that no remaining apertures in the assembled reservoir housing have a shape and/or size sufficient for removal of the spacer element. Alternatively or additionally, as set out further herein, the spacer element may be configured to be retained in a fixed position within the reservoir. This may comprise dimensioning the spacer such that upon insertion into the reservoir, portions of the external surface of the spacer interact mechanically with portions of the internal walls of the reservoir housing 2110 to hold the spacer in a fixed position relative to the reservoir, and/or using a bonding process to bond the spacer to the internal walls of the reservoir.

FIGS. 7A and 7B schematically show examples of a spacer element 400 according to the present disclosure. The spacer element 400 will be recognized from the spacer element 400 shown schematically in FIGS. 4A to 4D, and may be configured as set out in the accompanying description. In the present example, the geometry and material properties of the spacer element 400 are configured to enable the spacer element to be retained within the reservoir by mechanical interaction with the internal walls of the reservoir housing 2110 (and/or a reservoir housing portion 2112). FIG. 7A shows a section view along a plane oriented with axis Y down the centerline of an exemplary reservoir housing portion 2112 having a cylindrical internal volume. The reservoir housing portion 2112 may itself be comprised of further reservoir housing portions joined together according to approaches set out further herein. The internal diameter of the reservoir housing portion 2112 is d1, and the reservoir housing portion comprises an open end 2700. A spacer element 400 is provided, configured to cooperate with the reservoir housing portion 2112. In this example, the spacer element 400 is cylindrical, with an external diameter d2 which is larger than the internal diameter d1 of the reservoir housing portion 2112. The materials and geometry of the spacer element 400 and the reservoir housing portion 2112 are selected such that when the spacer element 400 is inserted into the reservoir housing portion, the spacer element is radially compressed, and/or the reservoir housing portion 2112 is radially extended, such that d2<d1. In general, the spacer element 400 will therefore be comprised of a resilient material, such as a plastics material. The spacer element may comprise a rubber material, for example a medical-grade silicone rubber material. The spacer element 400 may comprise a solid block of material, or comprise a hollow component comprising a sealed cavity within an outer wall or housing. In the latter case, the spacer may have a thin wall, which is impermeable to aerosolizable material such that the internal cavity and the wall together comprise the volume v2 of the spacer element which is impermeable to aerosolizable material. A spacer element comprising a thin-walled hollow element may comprise a metallic material. The spacer element may comprise a foam, for example a closed-cell foam comprised of expanded polymer, metal or ceramic.

The spacer element can be inserted into the reservoir housing portion 2112 in a number of ways. In the example shown in FIG. 7A, the spacer element 400 may be inserted into the opening of the reservoir housing portion 2112 along a direction S. Because the diameter d1 of the spacer element d1 is larger than the internal diameter of the reservoir housing portion 2112, the spacer element 400 will be radially compressed as it is inserted, and/or the reservoir housing portion 2112 may be radially expanded. The leading edge(s) 420 of the spacer and/or the edge(s) 2710 of the opening 2700 may be chamfered (not shown) to facilitate insertion of the spacer element into the reservoir housing portion 2112 along the direction S. FIG. 7B shows a configuration whereby the spacer element 400 has been fully inserted into the reservoir housing portion 2112. Due to the resilience of the spacer element 400 and/or the reservoir housing portion 2112, the radial compression of the spacer element and/or the radial expansion of the reservoir housing portion 2112 cause internal wall portions (e.g., 2126, 2124) of the reservoir housing portion 2112 to be biased against external wall portions (e.g., 412, 413) of the spacer element 400, causing the spacer element to be held within the reservoir housing portion 2112 by an interference fit. FIG. 7B shows a second reservoir housing portion 2111 joined to reservoir housing portion 2112 according to approaches set out further herein, and recognized from FIGS. 5A to 5D and the accompanying description, forming the assembled reservoir housing 2110 with a maximum available fill volume of V1′. However, in other cases the spacer element may not be configured to be fixed within the reservoir, and the diameter d2 of the spacer element may be equal to or smaller than the internal diameter d1 of the reservoir housing portion 2112.

In other examples, the spacer element 400 may have reservoir housing portions assembled around it during manufacture of the reservoir housing 2110. For example, two reservoir housing portions comprising halves of a cylinder split along the longitudinal axis may be brought together around a cylindrical spacer and joined to one another according to approaches set out further herein, such that the spacer element is in effect trapped within the internal space formed by the joining of the two reservoir housing portions. It will be appreciated that the spacer element 400 and reservoir housing portions can take other shapes as appropriate to the application. In some instances, the reservoir housing 2110 containing the spacer element may be openable by the user, for example to refill the reservoir 21. Accordingly, the reservoir housing portion 2111 as shown in FIG. 7B may thread onto the reservoir housing portion 2112 at the interface(s) 2210, or latch onto the reservoir housing portion 2112, or fit removably on or into the reservoir housing portion 2112 via an interference fit in the manner of a plug. What is significant is that once the spacer element is in place within the reservoir housing 2110, the user cannot remove the spacer element 400, either because the spacer element is fixed within the reservoir, and/or because the reservoir housing 2110 cannot be opened to remove the spacer element 400. Accordingly, provided the assembled reservoir housing 2110 is configured such that once introduced, the spacer element 400 cannot be removed without causing damage to the reservoir housing (e.g., because any remaining apertures are too small for the spacer to pass through) then the spacer element 400 may not be configured to be held in position within the reservoir, but may effectively be loose within the reservoir housing.

Though in the example schematically shown in FIGS. 7A and 7B, internal wall portions 2124 and 2126 of the reservoir housing portion 2112 are shown as parallel to one another, and the external wall portions 412 and 413 of the spacer element 400 configured to abut wall portions 2124 and 2126 are also shown as parallel to one another, it will be appreciated that in many instances this may not be the case. In situations whereby a spacer element 400 is configured to be inserted into an opening 2700 in a reservoir housing portion 2112, it will generally be the case that the internal walls of the reservoir housing portion 2112 are parallel, or slope such that the internal diameter of the recess 2130 within the reservoir housing portion 2112 becomes larger with progression from the end of the recess most distal from the opening 2700 to the end of the recess at which the opening 2700 is disposed. For instance, the internal volume of the reservoir housing 2110 or a reservoir housing portion 2112 (e.g., recess 2130) into which the spacer is to be received may be generally frustroconical in shape. The spacer element 400 will generally be shaped such that portions of the external surface configured to contact inner wall portions of the recess have a similar topology to said inner wall portions, albeit that the spacer element will be usually be dimensioned such that at least a portion of it is compressed as it is inserted into the recess 2130. For example, the spacer element 400 may have a frustroconical shape configured to be fitted within a basal portion of a frustroconical recess 2130 distal from an opening 2700. However, in other examples, where the spacer element 400 is configured to have a plurality of reservoir housing portions assembled around it during manufacture of a reservoir housing 2110 or reservoir housing portion 2112, the internal walls of the housing 2110 or reservoir housing portion 2112 may slope such that the internal diameter of the recess 2130 within it becomes smaller with progression from the end of the recess most distal from the opening 2700 to the end of the recess at which the opening is disposed. Accordingly, a spacer element 400 dimensioned with external wall portions which conform closely to internal wall portions of the assembled reservoir will not be removable once the reservoir housing portions 2120 have been assembled around it to form the reservoir housing 2110.

FIGS. 8A to 8D schematically show an example of a spacer element 400 and reservoir housing portion 2112/reservoir housing 2110 which are configured such that the when the spacer element 400 is inserted into the reservoir housing portion 2112/reservoir housing 2110, the spacer element 400 is retained in a fixed position within the internal volume of the reservoir housing portion 2112/reservoir housing 2110. Accordingly, FIG. 8A shows a spacer element 400 having one or more latching elements 430 which are configured to engage mechanically with portions 2800 of the internal walls of a reservoir housing portion 2112/reservoir housing 2110. The latching elements 320 may comprise elements which extend from the outer surface of the spacer element 400, such as dimples or tabs. The latching elements will generally be comprised of a resilient material such that they can deform when the spacer element 400 is introduced to the reservoir housing portion 2112. FIG. 8A shows exemplary latching elements 430 arranged in the form of sloped tabs. The portions of the internal walls of the reservoir housing portion 2112 may be configured with corresponding depressions or slots, which are configured to receive the latching elements 430 when the spacer element 400 is introduced to the reservoir housing portion 2112, thereby retaining the spacer element within the reservoir housing portion 2112. FIG. 8A shows exemplary depressions 2800 arranged in the form of sloped slots, each comprising an end-wall portion 2701 shaped to abut an end-wall portion 431 of a latching element 430. A sloping portion 432 of the latching elements may be provided to facilitate insertion of the spacer element into the opening 2700 of the reservoir housing portion 2112 along direction S. FIG. 8B schematically shows the spacer element 400 following insertion or incorporation into the reservoir housing portion 2112 such that the latching elements 430 are received into corresponding latching depressions 2800. In other respects the spacer element 400 may be configured as set out further herein. The end-wall portions 431 of the latching elements 430 are configured to abut the respective end-wall portions of the latching depressions 2800 such that once the spacer element is fixed in position within the reservoir housing portion 2112 it cannot be removed without causing damage to the latching elements 430 and/or the latching depressions 2800. Following insertion of the spacer element 400, a further reservoir housing portion 2111 may be joined to the reservoir housing portion 2112 at interface(s) 2210 in a manner as set out in the accompanying description to FIG. 7B. The spacer element 400 and reservoir housing portion 2112 may also be configured with resilient properties to facilitate an interference fit in addition to the mechanical engagement provided by the latching elements (as set out in the accompanying description to FIGS. 7A and 7B), and/or the reservoir housing 2110 may be assembled around the spacer element 400 as set out further herein instead of the spacer element 400 being inserted into the reservoir housing 2110 or a reservoir housing portion 2112. FIG. 8C shows detail of the region A of FIG. 8B, showing an arrangement in which the latching element 430 on the spacer element 400 comprises a depression or slot configured to engage with a cooperating latching tab or dimple 2800 on an internal wall of the reservoir housing portion 2112. As shown in FIGS. 8C and 8D, the latching tab in such embodiments may not comprise a flat end-wall portion as shown in FIGS. 8A and 8B, but may be a rounded dimple on either the spacer element 400 or the internal wall of the reservoir housing portion 2112. Any suitable shape of latching element and depression may be provided to retain a spacer element 400 within a reservoir 21 once the spacer element is present within the housing. In some examples (not shown) the latching element(s) 430 comprise a thread, configured to engage with corresponding thread(s) 2800 on the internal surface of the reservoir housing portion 2112, such that the spacer can be screwed into place within the reservoir housing 2110. The thread may incorporate a locking mechanism to only permit rotation of the spacer element in the tightening direction, preventing removal once it has been inserted. In some examples (not shown) the spacer element 400 is fixed in place within the reservoir 21 using magnets or permanent mechanical fixings such as rivets.

FIGS. 9A and 9B schematically show examples in which a spacer element 400 is fixed into position within a reservoir housing or reservoir housing portion 2112 via an adhesive or solvent bonding approach. The spacer 400 and reservoir housing portion 2112 may be configured according to any of the approaches set out further herein. However in the present example, a portion of adhesive or solvent 500 is introduced to a portion of an interface between the spacer element 400 and the internal walls of the reservoir housing portion 2112. FIG. 9A shows a reservoir housing portion 2112 which will be recognized from previous figures, with a spacer element 400 in place within a recess internal to the interior walls of the reservoir housing portion 2112. A portion of adhesive or solvent 500 is shown at the interface between the external walls of the spacer element 400 and the internal walls of the recess. An adhesive 500 suited to the material properties of the reservoir (for instance a polymer cement where the reservoir housing portion 2112 and spacer element 400 comprise plastics materials) may be introduced to the reservoir housing portion 2112 prior to or following insertion of the spacer element 400, forming an adhesive bond at a portion of the interface between the spacer element 400 and the reservoir housing portion 2112. A solvent 500 suited to the material properties of the reservoir (for instance an organic solvent where the housing portion 2112 and spacer element 400 comprise plastics materials) may be introduced to the reservoir housing portion 2112 prior to or following insertion of the spacer element 400, causing portions of the external walls of the spacer element and/or internal walls of the reservoir housing portion to be temporarily softened/dissolved, and to re-set upon evaporation of the solvent to form a bond at a portion of the interface between the spacer element 400 and the reservoir housing portion 2112. FIG. 9B shows an assembled reservoir housing 2110 comprising reservoir housing portions 2112 and 2111 which may be joined according to permanent or reversible joining methods described further herein at interface(s) 2210, whereby the solvent/adhesive 500 has formed a bond permanently fixing the spacer element 400 within the internal space of the reservoir.

As set out further herein, in some examples the spacer element 400 is introduced to the internal space of a reservoir housing 2110 or reservoir housing portion 2112 by assembling a plurality of reservoir housing portions around the spacer element 400 during manufacture of the reservoir 21. In some instances, where a reservoir housing 2110 or reservoir housing portion 2112 is manufactured by molding techniques (e.g., injection molding, blow molding, compression molding, extrusion molding or thermoforming), a spacer element 400 may be incorporated into an internal recess of the reservoir housing 2110 or reservoir housing portion 2112 during the molding process. In many instances, the spacer element 400 will not be configured to be removable from the recess once the molding process is complete, due to adhesion and/or mechanical interference between the reservoir housing 2110 or reservoir housing portion 2112 and the spacer element 400. FIGS. 10A to 10C schematically show examples of an approach according to which a spacer element 400 may be incorporated into a reservoir housing 2110 or reservoir housing portion 2112 during a molding process. FIG. 10A shows a mold 600 for a molding process (e.g., an injection molding process), comprising an external mold portion 610 and a mandrel 620. Together the external mold portion 610 and the mandrel 620 define an internal cavity 630 to which a liquid or semi-liquid molding material (e.g., plastic, ceramic, glass or metal) is introduced to form a reservoir housing 2110 or reservoir housing portion 2112. A spacer element 400 is shown within the internal cavity 630, which in this instance is temporarily attached to the mandrel (for instance via suction) whilst the mold is arranged and the molding material is introduced. FIG. 10B shows the mold 600 with a molding material 700 having been introduced to the internal cavity 630 via the apertures indicated via the arrows A, substantially filling the portion of the internal cavity not occupied by the spacer element 400. FIG. 10C shows the mold 600 following setting of the molding material, with the mandrel 620 having been removed along the direction indicated by the arrow S. The molding material 700 has solidified to produce a reservoir housing 2110 or reservoir housing portion 2112, having a portion of its internal volume occupied by the spacer element 400. FIG. 10D shows an example of a reservoir housing portion 2112 which has had a spacer element 400 incorporated during molding, and has been removed from the external mold 610, and sealed with a reservoir housing portion 2111 according to any of the approaches set out further herein. The internal fill volume V1′ is shown filled with aerosolizable material, indicated by the shaded region. In this example, the diameter of the spacer 400 is configured to be larger than that of the mandrel 620, such that once the reservoir housing portion 2111 is molded around the spacer and the mandrel, wall portion(s) 2701 of the housing abut the upper surface of the spacer element 400 and retain it mechanically within the reservoir 21. However, this is not essential, and in other examples the spacer element may be fixed within the reservoir according to other approaches set out further herein. FIGS. 10E and 10F show different reservoir housings comprising reservoir housing portions 2112 molded using the mold 600 shown in FIGS. 10A to 10C. However in FIGS. 10E and 10F, the spacer element 400 geometries are different to the spacer element geometry shown in FIG. 10D. Specifically, the spacer element 400 in FIG. 10E has a smaller internal volume V2 than that of the spacer element 400 shown in FIG. 10D, such that the available fill volume V1′ of the reservoir 21 shown in FIG. 10E is larger than that of the reservoir 21 shown in FIG. 10D. Similarly, the spacer element 400 in FIG. 10F has a smaller internal volume V2 than that of the spacer element 400 shown in FIG. 10E, such that the available fill volume V1′ of the reservoir 21 shown in FIG. 10F is larger than that of the reservoir 21 shown in FIG. 10E. By providing spacer elements 400 having different geometries (e.g., having differently sized internal recesses or cut-outs), the same mold can be used to produce reservoir housings 2110 having different available fill volumes V1′, by changing the geometry of the spacer element 400. This may provide a more cost effective means to produce reservoirs having different available fill volumes than using different molds to produce each specific volume variant.

In many instances, the reduction of the available fill volume of the reservoir 21 upon insertion of the spacer element 400 will be provided by the spacer element 400 being configured with an internal volume V2 which is impermeable and/or inaccessible to aerosolizable material to be stored in the reservoir 21, such that the available fill volume V1′ of the reservoir 21 including the spacer element 400 is approximately given by V1′=V1-V2, where V1 is the internal volume of the reservoir without the spacer. However, in some cases, some of the reduction in the available fill volume when the spacer element 400 is inserted is partially provided by the spacer element partitioning the internal space of the reservoir into a portion V1′ which is accessible to aerosolizable material, and a portion V3 which is not accessible to aerosolizable material. FIG. 11 shows a reservoir housing 2110 comprising two reservoir housing portions 2111 and 2112 joined together (though any number of reservoir housing portions may be joined together to form a reservoir housing, or the reservoir housing 2110 may be an integrally formed unitary body). A spacer element 400 has been introduced to the internal space of the reservoir housing 2110 according to any of the approaches set out further herein. In this specific example, the spacer element 400 has been provided with latching elements with engage with slots on the internal wall of the reservoir housing 2110 to hold the reservoir spacer in position. The spacer element is thereby fixed in a position which spans a cross section of the internal recess of the reservoir housing 2110, partitioning it into a volume V1′ which is able to be filled with aerosolizable material, and a volume V3 which is partitioned off from volume V1′ such that aerosolizable material from volume V1′ cannot pass into volume V3. This partitioning may require a seal (for example, a liquid- or gas-tight seal) to be formed at the interface between the spacer element 400 and the internal walls of the reservoir housing 2110. This seal may be formed by the spacer element 400 and the internal walls of the reservoir housing 2110 being biased against each other. For example, the spacer element 400 may comprise silicone rubber, or be configured with a rubber gasket at the interface between the spacer element 400 and the internal walls of the reservoir housing 2110. Adhesive or welding approaches may be used to seal the spacer element 400 against the internal walls of the reservoir housing 2110, or the spacer element may be molded into the reservoir housing 2110 in the manner described in relation to FIGS. 10A to 10F.

The foregoing examples have described a spacer comprising a unitary body which is inserted or incorporated into a reservoir housing 2110. However, in other embodiments, the spacer element 400 may comprise a quantity of beads, granules, particles, liquid or gel which is introduced to the internal space of a reservoir housing 2110. The available fill volume V1′ of a reservoir with a maximum volume of V1 may be controlled or modified by introducing a volume V2 of beads, granules, particles, liquid or gel to the internal space of a reservoir housing 2110 comprising the reservoir, such that the available fill volume is V1′=V1−V2. FIG. 12 shows a reservoir housing 2110 to which a spacer element 400 comprising a volume of liquid has been introduced. The liquid may be introduced into an internal recess of a reservoir housing portion 2112 which is subsequently joined to one or more further reservoir housing portions to form the reservoir housing 2110 as set out further herein. The liquid may be introduced to the internal space of the reservoir housing 2110 via an aperture 2500 (not shown) which is subsequently sealed according to approaches as set out further herein (for example, see the accompanying description to FIGS. 6A and 6B). The liquid may be introduced to the internal space of the reservoir housing 2110 via a one-way valve, for example a valve used to fill and/or refill the reservoir 21 with aerosolizable material. In some examples, the liquid is configured to solidify once introduced to the internal space of the reservoir housing 2110. For example the liquid may comprise a resin which cures once introduced to the internal space of the reservoir housing 2110. This curing process may be facilitated and/or accelerated by subjecting the filled reservoir housing 2110 to heat or radiation (e.g., ultraviolet radiation). In other examples, the liquid or gel may remain in liquid or gel form, but be configured so as to be immiscible with the aerosolizable material to be stored in the reservoir 21. The liquid chosen for the spacer should be substantially inert so as not to taint the aerosolizable material to be stored in the reservoir. Moreover, where the aerosolizable material to be stored in the reservoir 21 comprises a liquid, the liquid transport arrangement (e.g., a wick) used to transport aerosolizable material from the reservoir 21 to the aerosol generating component 22 may need to be chosen so as to be selective to the aerosolizable material, such that the liquid comprising the spacer element 400 cannot be absorbed or otherwise transported by the wick. In other examples, the spacer element 400 comprises beads or granules, for example polymer, ceramic or glass beads or granules which may be introduced to the internal space of the reservoir housing 2110 in any of the ways described for a spacer element 400 comprising a liquid. FIG. 13 schematically shows a reservoir housing 2110 to which a spacer element 400 comprising a volume of granules has been introduced. In many instances, the approach used to form the reservoir housing 2110 (whether the reservoir housing is formed integrally, or via joining of a plurality of reservoir housing portions) is such that the reservoir housing cannot be opened to remove the spacer element 400 comprising the liquid, beads or granules once they have been introduced. This approach can prevent the user being able to modify the available fill volume V1′ of the reservoir 21′, which may be important for preventing the user breaking regulations controlling the quantity of aerosolizable material which can be stored in a cartridge/cartomizer/aerosol delivery device.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the disclosure, and that other embodiments may be utilized and modifications may be made without departing from the scope of the disclosure. Various embodiments of the disclosure may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include inventions not presently claimed, but which may be claimed in future. 

1. An article for use with a non-combustible aerosol delivery system, the article comprising a reservoir configured to hold a supply of aerosolizable material; wherein the reservoir comprises a reservoir housing having one or more internal boundary walls defining a first volume, and wherein the article further comprises a spacer fully or partially located within the first volume of the reservoir housing, the spacer being configured to reduce an available fill volume of the reservoir, such that a second volume of the reservoir housing available for storing aerosolizable material is smaller than the first volume.
 2. The article according to claim 1, wherein the article further comprises an aerosol generating component.
 3. The article according to claim 2, wherein the aerosol generating component is not located within the reservoir.
 4. The article according to claim 1, configured such that the spacer cannot be removed from the article without damaging the article.
 5. The article according to claim 4, wherein configuring the article such that the user cannot remove the spacer without causing damage to the article comprises locating the spacer within the reservoir housing during manufacture of the reservoir housing.
 6. The article according to claim 1, wherein the reservoir housing is configured with an aperture via which the spacer can be introduced to the reservoir housing, and wherein the aperture is configured to be non-reversibly sealed following the introduction of the spacer such that the spacer cannot be removed from the reservoir via the aperture.
 7. The article according to claim 6, wherein the aperture is sealed via a process selected from the set consisting of welding, adhesive bonding and mechanical fastening.
 8. The article according to claim 6, wherein the aperture comprises a one-way valve which permits the spacer to be introduced into the reservoir but prevents the spacer being removed from the reservoir.
 9. The article according to claim 1, wherein assembling the reservoir housing comprises joining together a plurality of reservoir housing portions via one or more assembly steps to form the reservoir housing, and wherein the spacer is incorporated into the internal volume of the reservoir housing during assembly of the reservoir.
 10. The article according to claim 9, wherein the reservoir housing portions are joined together via processes selected from the set consisting of welding, adhesive bonding, solvent bonding, and mechanical fastening.
 11. The article according to claim 1, wherein the spacer is configured to be attached to one or more internal boundary walls of the reservoir housing.
 12. The article according to claim 11, wherein at least a portion of an external surface of the spacer is configured to interact mechanically with at least a portion of one or more of the internal walls of the reservoir housing so as to retain the spacer in a fixed position relative to the reservoir.
 13. The article according to claim 12, wherein at least one of the spacer and the reservoir housing is formed of a resilient material, such that at least one of the topology of one or more portions of the outer surface of the spacer and the topology of one or more portions of the internal walls of the reservoir deform when the spacer is introduced to the reservoir, such that a portion of the outer surface of the spacer and a portion of one or more of the boundary walls of the reservoir are biased into contact with one another when the spacer is located within the reservoir housing.
 14. The article of claim 12, wherein the spacer comprises at least one latching feature configured to engage mechanically with at least one cooperating latching feature on a boundary wall of the reservoir when the spacer is located within the reservoir housing.
 15. The article of claim 14, wherein the latching feature comprises a tab, groove or depression formed in the spacer.
 16. The article according to claim 11, wherein at least a portion of an external surface of the spacer is configured to be bonded to at least a portion of one or more of the boundary walls of the reservoir.
 17. The article according to claim 16, wherein at least a portion of an external surface of the spacer is configured to be bonded to at least a portion of one or more of the boundary walls of the reservoir, using a process selected from the set consisting of an adhesive bonding process, a welding process, or a solvent bonding process.
 18. The article according to claim 1, wherein a portion of the reservoir is formed via a molding process, and wherein the spacer is introduced to the mold before or during the molding process such that a portion of the reservoir housing is formed around the spacer.
 19. The article according to claim 1, wherein the spacer engages with the internal walls of the reservoir housing so as to partition the first volume into two partitioned volumes, such that aerosolizable material introduced to a first one of the two partitioned volumes is substantially prevented from passing into the second one of the two partitioned volumes, and wherein the article is configured such that the volume of the first one of the two partitioned volumes is smaller than the first volume.
 20. The article according to claim 1, wherein the spacer comprises a liquid.
 21. The article according to claim 1, wherein the spacer comprises a plurality of granules, particles or beads.
 22. The article according to claim 20, wherein the spacer is immiscible with an aerosolizable material to be stored in the reservoir.
 23. The article according to claim 20, wherein the liquid changes state to form a gel or solid following introduction to the reservoir housing.
 24. A spacer for use with an non-combustible aerosol delivery system comprising a reservoir configured to hold a supply of aerosolizable material, wherein the reservoir comprises a reservoir housing having one or more internal boundary walls defining a first volume, wherein the spacer is configured to be fully or partially located within the first volume of the reservoir housing; and wherein the spacer is configured to occupy a portion of the first volume of the reservoir housing, such that a second volume of the reservoir housing not occupied by the spacer is smaller than the first volume. 